Terminal Block

The present application claims priority to and incorporates by reference the entire contents of Japanese Patent Application No. 2024-086081 filed in Japan on May 28, 2024.

The present invention relates to a terminal block.

As a technique related to a terminal block in the related art, for example, JP 2022-024667 A discloses a terminal block including a bus bar provided with a first connection portion connected to a first connection terminal, a second connection portion connected to a second connection terminal, and an intermediate portion connected between the first connection portion and the second connection portion; and a housing provided with an insertion space portion into which the second connection portion of the bus bar is inserted.

Here, the terminal block disclosed in JP 2022-024667 A has room for further improvement in terms of absorbing a tolerance between the first connection terminal and the second connection terminal, for example.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a terminal block capable of absorbing a tolerance between a first connection terminal and a second connection terminal.

In order to achieve the above mentioned object, a terminal block according to one aspect of the present invention includes a bus bar including a first connection portion extending along an axial direction and connected to a first connection terminal, a second connection portion extending along the axial direction and positioned to be shifted in a plate thickness direction intersecting the axial direction and the axial direction with respect to the first connection portion and connected to a second connection terminal, and an intermediate portion connected between the first connection portion and the second connection portion and extending along the plate thickness direction; a housing provided with an insertion space portion into which the second connection portion of the bus bar is inserted along the axial direction; a packing that is inserted into the insertion space portion together with the second connection portion and seals an annular space between an outer surface of the second connection portion and an inner surface of the insertion space portion; and a packing holder provided with a bus bar insertion portion through which the second connection portion is inserted along the axial direction, the packing holder being inserted into the insertion space portion in a state where the second connection portion is inserted into the bus bar insertion portion, and the packing is supported in the axial direction, wherein the bus bar insertion portion is configured to include a first gap for allowing deformation of the second connection portion in the plate thickness direction.

The above and other objects, features, advantages and technical and industrial significance of this invention will be better understood by reading the following detailed description of presently preferred embodiments of the invention, when considered in connection with the accompanying drawings.

Hereinafter, embodiments according to the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited by the following embodiments. In addition, constituent elements in the following embodiments include those that can be easily replaced by those skilled in the art, or those that are substantially the same. In the present specification, ordinal numbers are used only to distinguish components, members, parts, positions, directions, and the like, and do not indicate order or priority.

is a perspective view of a terminal blockaccording to an embodiment. The terminal blockof the present embodiment illustrated inis mounted on a vehicle such as an electric car or a hybrid car, for example, and relays electrical connection between a first device Dand a second device D. The terminal blockof the present embodiment includes a plurality of bus bars, and a first connection terminal(refer to) of the first device Dis electrically connected to a first connection portionprovided at one end portion of the plurality of bus bars. In the terminal blockof the present embodiment, a second connection terminalof the second device Dis electrically connected to a second connection portionprovided at the other end portion of the plurality of bus bars. The first device Dis, for example, one of a motor and an inverter, and the second device Dis, for example, the other of the motor and the inverter. Note that the terminal blockis not limited to this example, and may be used for, for example, relaying between the first device Dor the second device Dand a wiring member, relaying between the wiring member and the wiring member, or the like.

In the following description, among a first direction, a second direction, and a third direction intersecting each other, the first direction is referred to as an “axial direction X”, the second direction is referred to as a “width direction Y”, and the third direction is referred to as a “plate thickness direction Z”. Here, the axial direction X, the width direction Y, and the plate thickness direction Z are substantially orthogonal to each other. Typically, the axial direction X corresponds to an extending direction of the plurality of bus bars, an insertion direction of the plurality of bus barsinto a housing, a depth direction (front-rear direction) of the terminal block, or the like. The width direction Y typically corresponds to a width direction of the plurality of bus bars, a width direction (left-right direction) of the terminal block, or the like. The plate thickness direction Z typically corresponds to a plate thickness direction of the plurality of bus bars(the first connection portionand the second connection portion), a fastening direction of the plurality of bus barsand the first connection terminaland the second connection terminal, a height direction (vertical direction) of the terminal block, or the like. Each direction used in the following description will be described as a direction in a state where the terminal blockis assembled to the first connection terminaland the second connection terminalunless otherwise specified.

is an exploded perspective view of the terminal block. As illustrated in, the terminal blockincludes, for example, the plurality of bus bars, a housing, a packing, a packing holder, and a seal member. The plurality of bus barsare terminal fittings made of a conductive metal material, and are electrically connected to the first connection terminaland the second connection terminaldescribed above. In the present embodiment, the terminal blockis provided with three bus barsarranged in the width direction Y. The number of the bus barsis not limited to this example, and for example, one, two, or four or more bus barsmay be provided.

The bus barincludes, for example, the first connection portionprovided at one end portion in the axial direction X, the second connection portionprovided at the other end portion in the axial direction X, and an intermediate portionprovided between the first connection portionand the second connection portion. The first connection portion, the second connection portion, and the intermediate portionare integrally formed of a conductive metal material. That is, the bus baris formed such that each portion is three-dimensionally integrated into a crank shape by performing various processing such as bending processing on one sheet of metal in accordance with the shape corresponding to each portion of the first connection portion, the second connection portion, and the intermediate portion.

The first connection portionis a portion electrically and mechanically connected to the first connection terminal. The first connection portionextends along the axial direction X. The first connection portionis provided with an attachment holeto which a bolt(refer to) of a fastening memberfor fastening the bus barand the first connection terminalis attached. The attachment holeis a through hole penetrating the first connection portionalong the plate thickness direction Z, and is configured as a round hole having a larger diameter than a shaft portionof the bolt.

The second connection portionis a portion electrically and mechanically connected to the second connection terminal. The second connection portionextends along the axial direction X and is positioned to be shifted from the first connection portionin the axial direction X and in the plate thickness direction Z. The second connection portionis provided with an attachment holeto which a bolt(refer to) of a fastening memberfor fastening the bus barand the second connection terminalis attached. The attachment holeis a through hole penetrating the second connection portionalong the plate thickness direction Z, and is configured as a round hole having substantially the same diameter as a shaft portionof the bolt.

The intermediate portionis a portion connected between the first connection portionand the second connection portion. The intermediate portionextends along the plate thickness direction Z and forms a step between the first connection portionand the second connection portion. The intermediate portionis bent at an angle of 90° with respect to the first connection portionand the second connection portion, for example. The thickness direction of the intermediate portionis along the axial direction X intersecting the plate thickness direction Z of the first connection portionand the second connection portion.

The housingholds the second connection portionsof the three bus barsarranged in the width direction Y, and is formed of an insulating synthetic resin material. The housingis provided with, for example, a housing main bodyand a housing protrusionprotruding from the housing main bodyto the side opposite to the bus baralong the axial direction X. In the housing, the housing main bodyand the housing protrusionare integrally formed.

An insertion space portioninto which the second connection portionof the bus baris inserted along the axial direction X is provided inside the housing main bodyand the housing protrusion. The insertion space portionpenetrates the housing main bodyand the housing protrusionalong the axial direction X. In the present embodiment, the housingis provided with three insertion space portionscorresponding to the bus bars, and these three insertion space portionsare partitioned from each other in the width direction Y.

The housing main bodyhas one end faceon one side (bus barside) in the axial direction X and the other end faceon the other side in the axial direction X. The one end faceis a portion facing the intermediate portionof the bus barin the axial direction X in a peripheral edge portion of the insertion space portion. The other end faceis a portion provided with a recessfor holding the seal memberin the peripheral edge portion of the housing protrusion. The recessis recessed from the other end facetoward one side in the axial direction X and opened toward the other side in the axial direction X. The recessis formed in, for example, a substantially elliptical annular shape along the outer shape of the seal member.

The seal membersuppresses entry of foreign matter such as moisture into the terminal blockthrough an annular gap between the housingand a cylindrical portion (not illustrated) of the second device D. The seal memberis formed of an elastically deformable member such as rubber or resin. The seal memberis formed in, for example, a substantially elliptical tubular shape and is fitted into the recessdescribed above. The seal memberis interposed between the other end faceof the housing main bodyand an end face of a cylindrical portion (not illustrated) of the second device Din a state where the terminal blockis connected to the second device D.

is a perspective view of the packingof the terminal block. As illustrated in, the packingis provided with, for example, an insertion holethrough which the second connection portionof the bus baris inserted along the axial direction X, and seals the periphery of the second connection portion. In the present embodiment, the terminal blockis provided with three packingscorresponding to the bus bars. For example, the three packingsare connected to each other via a coupling portionprovided between two adjacent packingsin the width direction Y. The packingis formed of, for example, an elastically deformable member such as rubber. The packingis also referred to as a terminal packing, a rubber plug, a bush, or the like.

The packingis provided with a plurality of outer peripheral lip portionsand a plurality of inner peripheral lip portions. The outer peripheral lip portionis a pleated water stop portion formed in a substantially annular shape along the outer peripheral surface of the packing. In the present embodiment, the packingis provided with two outer peripheral lip portionsarranged side by side in the axial direction X. In a state where the packingis mounted in the insertion space portion(refer to) of the housing, the outer peripheral lip portioncomes into contact with the inner surface of the insertion space portionand waterproofs between the outer peripheral lip portion and the inner surface. The outer peripheral lip portionis configured to come into close contact with the inner surface of the insertion space portionby elastic deformation and seal the annular space between the inner surface and the outer peripheral surface of the packing.

The inner peripheral lip portionis a pleated water stop portion formed in a substantially annular shape along the inner peripheral surface of the packing. In the present embodiment, the packingis provided with two inner peripheral lip portions(refer to) arranged side by side in the axial direction X. In a state where the second connection portionof the bus baris inserted (press-fitted) into the insertion hole, the inner peripheral lip portioncomes into contact with the outer surface of the second connection portionand waterproofs between the inner peripheral lip portion and the outer surface. The inner peripheral lip portionis configured to come into close contact with the outer surface of the second connection portionby elastic deformation and seal an annular space between the outer surface and the inner peripheral surface of the packing.

is a perspective view of the packing holderof the terminal block, andis a sectional view of the terminal block. As illustrated in, the packing holderis provided with, for example, a bus bar insertion portionthrough which the second connection portionof the bus baris inserted along the axial direction X, supports the periphery of the second connection portion, and supports the packingin the axial direction X. In the present embodiment, the packing holderis provided with three bus bar insertion portionscorresponding to the bus bars. The three bus bar insertion portionsare partitioned from each other in the width direction Y via a partition wallprovided between two bus bar insertion portionsadjacent to each other in the width direction Y, for example. The packing holderis formed of, for example, an insulating synthetic resin material.

In addition, the packing holderis provided with, for example, a protrusionprovided on one end face in the axial direction X. The protrusionprotrudes from the packing holderto one side in the axial direction X and supports the intermediate portion(refer to) of the bus bar. That is, the protrusionsupports the intermediate portionin a state of being separated from one end face of the packing holderin the axial direction X. The packing holderis inserted into the insertion space portionof the housingin a state where the second connection portionis inserted into the bus bar insertion portionand the packingis supported in the axial direction X. The packing holderfunctions as a portion that pushes the packingtoward the other side in the axial direction X (the back side) at the time of assembly to the insertion space portion.

In addition, in a state where the packing holderis assembled to the insertion space portion, a second gap Sis provided between the intermediate portionand one end face of the packing holderin the axial direction X and between the intermediate portionand the one end faceof the housingdescribed above. The second gap Sis a gap for allowing deformation of the intermediate portionin the axial direction X.

Here, in the present embodiment, the bus bar insertion portionis configured to include a first gap Sfor allowing deformation of the second connection portionin the plate thickness direction Z. The first gap Sis, for example, a gap between an inner surface on the other side in the plate thickness direction Z of the bus bar insertion portionand the second connection portionin a state where the second connection portionis in contact with the inner surface on one side in the plate thickness direction Z of the bus bar insertion portion. In the present embodiment, an opening width Wof the first gap Salong the plate thickness direction Z is set to be larger than a thickness Wof the second connection portionalong the plate thickness direction Z. The bus bar insertion portionhas an opening width obtained by adding the opening width Wof the first gap Sand the thickness Wof the second connection portion.

Next, a tolerance absorbing structure at the time of assembly work on the first connection terminaland the second connection terminalof the terminal blockhaving the above configuration will be described.is a sectional view of the terminal blockin a state where the bus baris deformed. As illustrated in, when the terminal blockis assembled to the first connection terminaland the second connection terminal, first, the second connection portionof the bus barand the second connection terminalof the second device Dare fastened and fixed by the fastening member.

Specifically, in the present embodiment, the fastening memberincludes a boltand a nut, and the nutis attached and fixed to the distal end portion of the housing protrusionin advance in a state of being aligned in the plate thickness direction Z with the attachment holeof the second connection portion. The boltis provided with the shaft portionhaving an outer peripheral surface provided with a male screw portion that meshes with a female screw portion of the nut, and a head portionhaving a larger diameter than the shaft portion. In a state where the second connection terminaland the second connection portionare sandwiched between the head portionand the nut, the shaft portionof the boltpenetrates the second connection terminaland the second connection portionin the plate thickness direction Z and is fastened to the nut.

Next, the first connection portionof the bus barand the first connection terminalof the first device Dare fastened and fixed by the fastening member. Specifically, in the present embodiment, the fastening memberincludes the boltand a nut, and the attachment holeof the first connection terminalto which the shaft portionof the boltis attached is configured as a round hole for absorbing a dimensional tolerance between the first connection terminaland the second connection terminalto some extent. In a state where the first connection terminaland the first connection portionare sandwiched between a head portionand the nut, the shaft portionof the boltpenetrates the first connection terminaland the first connection portionin the plate thickness direction Z and is fastened to the nut.

At this time, in the present embodiment, when the dimensional tolerance between the first connection terminaland the second connection terminalis relatively large, an external force obliquely downward between the axial direction X and the plate thickness direction Z is generated in the bus bar, and the stress concentrates in the vicinity of the intermediate portionto deform a proximal end portionof the second connection portionalong the plate thickness direction Z. The proximal end portionis an end portion of the second connection portionon the intermediate portionside. In addition, the intermediate portionmay be deformed along the axial direction X due to stress concentrated in the vicinity of the intermediate portion. Accordingly, the terminal blockcan absorb dimensional tolerance between the first connection terminaland the second connection terminal.

As described above, in the terminal blockaccording to the present embodiment, the bus bar insertion portionis configured to include a first gap Sfor allowing deformation of the second connection portionin the plate thickness direction Z. With this configuration, the terminal blockcan allow the second connection portionto be deformed in the plate thickness direction Z by the first gap Sat the time of assembly to the first connection terminaland the second connection terminal. As a result, the terminal blockcan absorb the tolerance between the first connection terminaland the second connection terminal, and can further reduce the stress generated in the bus bar, thereby improving the assemblability with respect to the first connection terminaland the second connection terminal.

In addition, in the terminal blockaccording to the present embodiment, the opening width Wof the first gap Sin the plate thickness direction Z is larger than the thickness Wof the second connection portionin the plate thickness direction Z. With this configuration, the terminal blockcan secure, for example, a relatively wide space in which the second connection portionis deformed along the plate thickness direction Z by the first gap Sat the time of assembly to the first connection terminaland the second connection terminal. In addition, for example, as compared with a case where the opening width of the bus bar insertion portionincluding the first gap Salong the plate thickness direction Z is configured to be substantially the same as or slightly larger than the thickness Wof the second connection portionalong the plate thickness direction Z, that is, a case where the second connection portionhas no space to be deformed along the plate thickness direction Z or is relatively small, it is possible to further reduce the stress generated in the bus barat the time of assembly to the first connection terminaland the second connection terminal.

Further, in the terminal blockof the present embodiment, the housinghas one end facefacing the intermediate portionin the axial direction X at the peripheral edge portion of the insertion space portion, and the second gap Sfor allowing deformation of the intermediate portionin the axial direction X is provided between the one end faceand the intermediate portion. With this configuration, the terminal blockcan allow the intermediate portionto be deformed in the axial direction X by the second gap Sat the time of assembly to the first connection terminaland the second connection terminal, for example. As a result, the terminal blockcan absorb the tolerance between the first connection terminaland the second connection terminal, and can thus improve the assemblability with respect to the first connection terminaland the second connection terminal.

Further, in the present embodiment, the case where the second gap Sfor allowing the deformation of the intermediate portionin the axial direction X is provided between the one end faceand the intermediate portionhas been exemplified, but the present invention is not limited to this example. For example, the one end faceand the intermediate portionmay be arranged in a state of being in contact with each other without providing the second gap S.

In the terminal block according to the present embodiment, the bus bar insertion portion is configured to include a first gap for allowing deformation of the second connection portion in the plate thickness direction. With this configuration, the terminal block can allow the second connection portion to be deformed in the plate thickness direction by the first gap at the time of assembly to the first connection terminal and the second connection terminal. As a result, the terminal block can absorb the tolerance between the first connection terminal and the second connection terminal.

Although the invention has been described with respect to specific embodiments for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art that fairly fall within the basic teaching herein set forth.